Braumat V7.5 is released! Now Braumat is running on the S7-400 and S7-1500!

The industry-specific operator control and monitoring system - especially for controlling and monitoring recipe-controlled production processes such as those in breweries.

1. Overview of the range of functions

BRAUMAT / SISTAR is the proven operator control and monitoring system for recipe-controlled production processes (such as those in breweries). Based on the Siemens Totally Integrated Automation (TIA) concept, BRAUMAT / SISTAR offers the following advantages and benefits in engineering and reliable plant operation:

Based on rugged industry standard components, SIMATIC S7 and IPC

Flexible and easy integration of field devices and drives based on PROFIBUS and PROFINET

Scalable from the smallest unit up to a large plant network

Modular control system with modern distributed client-server architecture

Increased availability through optional server redundancy

Efficient and plant-wide engineering

Simple and quick system expansion and optimization in runtime

What's new in V7.5?

Support for the new CPU generation S7-1500

In addition to the previously supported CPU type, SIMATIC S7-400, the new S7-1500 CPU generation is also supported as of product version V7.5.

As a modern automation system, CPU S7-1500 offers many new and expanded features for efficient, reliable and safe production operation:

Highest performance

Higher performance processors and more memory expand configuration limits and reduce response times

Integrated system diagnostics

The integrated diagnostic functionality makes it possible to quickly identify and eliminate the sources of errors. This reduces downtimes and causes of errors.

Security Integrated

The modern and multi-level security concept of SIMATIC S7-1500 includes measures that range from authorization levels and device protection to communication integrity. This ensures reliable protection of your know-how, product quality and production itself.

You can find additional details on the new features of the S7-1500 here:

SIMATIC Controller S7-1500

Engineering and programming of the S7-1500 CPU is performed with the new version of STEP 7 in the TIA Portal. Thanks to new editors and central data management, the TIA Portal enables more efficient and intuitive engineering:

You can find additional details on the new options of STEP 7 in the TIA Portal here: STEP 7 (TIA Portal)

You can find details on the released CPU types for BRAUMAT / SISTAR and the functional limitations of this first stage of release in the enclosed readme document.

The new replay mode for BRAUMAT / SISTAR V7.5 records all relevant process values and parameters of the production process and enables you to fast forward, slow forward and rewind as well as to pause your process screens based on the recorded process data:

Typical application cases are, for example:

Simple diagnostics and reproduction of faults enables the cause to be quickly found and eliminated - especially when the faults occur sporadically

Analysis and traceability of causes for quality fluctuations of individual batches

Documentation of production conditions of batches

The process screens in replay mode can be displayed in a separate window parallel to your real-time process screens - this does not influence the operation and monitoring of the running production process.

The runtime dialogs are now "multi-instance enabled", i.e. multiple blocks can be opened at the same time

Uniform symbol identifiers in runtime for interlock, simulation, manual, notice (new) for all control types

Symbol identifiers can be set for each block instance in the properties dialog (default setting can be defined for each class in 'Controls.ini')

Entity-OCX font can be set

New controls for tank/pipe status block

New OCX symbols (emf/vector graphics)

Plant overview (SeqCtrl)

New self-explanatory unit status symbols

Display column for recipe category for the current batch for each unit

Engineering

New system classes

BLR

Binary logic operations can be modeled in a stand-alone object that can be configured graphically and undergo operator control and monitoring. This type of BLR ("Binary Logic Result") object is suitable for use as:

Interlock of an ICM

Permanent condition of a plant unit

Step-enabling condition of a step block (EOP-FC)

DFM4

Simple configuration limit expansion of DFM1 functionality.

DFM5 to DFM8

Expansion of DFM1 functionality with practically the same functions, but based on REAL data type.

Changes to system classes

General

All analog signal-processing blocks use the REAL data type.

The "Reference" data type replaces QUEL.

AOUT

The process I/O is incorporated based on a reference. The "AOUT_PW" allocation class previously responsible for this is omitted.

AIN

The process I/O is incorporated based on a reference. The "AIN_PW" allocation class previously responsible for this is omitted.

The measured value can be smoothed.

SEQUENCE

Configuration limit increase to 128 instances

Permanent condition is freely configurable (reference)

TIMER

The process connection can be released from the standard mapping by using references for input and output signals.

"Parameterization" application

New data types

DT (S7 data type DATE_AND_TIME)

ENUM (enumerations based on system or project text files)

OREF (Object reference, comparable with the previous QUEL data type)

GREF/PREF ("Get/Put-Reference": Data connection to any PCU memory areas in the same PCU)

New recipe DFM types

Text (bit field)

Individual bits of a double word with texts can be linked in the context of DFM usage (e.g. recipe editor, plant overview). With this Option it is possible, to select functions and outputs by recipe-functionality depending from a Step.

Direct selection of the ICM-Output by recipe

Direct activation of Functions / modules

"ZL Synchronizer" application

The process for selecting BRAUMAT object classes for synchronization with the Step 7 symbol table has been enhanced. The following system classes are now available:

This function block manages the tank and container statuses and provides runtime monitoring with interfaces and alarms for process and quality status for this purpose, including an operating and monitoring interface.

Based on the general approach the block can be used for a large variety of different container types, e.g. silos, buffer tanks, etc.

The process status allows up to 255 (10 upon delivery) tank statuses to be managed and can be operated via OS faceplate and/or control inputs.

The process status allows up to 255 (4 upon delivery) tank statuses to be managed and can be operated via OS faceplate and/or control inputs.

There are 3 separate timers available for monitoring the remaining runtimes for material quality, tank cleaning, and tank sterility.

The material is selected in the OS faceplate on the basis of the materials defined in the material configuration dialog.

Up to 8 temperature sensors can be connected to the block and be activated/deactivated (via configured references or via user allocation). The display in the faceplate and the calculation of the average temperature value occur based on the activation information.

Line status block

This function block manages the pipeline statuses and provides runtime monitoring with interfaces and alarms for the process status for this purpose, including an operating and monitoring interface.

Based on the general approach the block can be used for a large variety of different line types.

The process status allows up to 255 (10 upon delivery) line statuses to be managed and can be operated via OS faceplate and/or control inputs.

There is a timer available for monitoring the remaining runtime for any desired process status.

The material is selected in the OS faceplate on the basis of the materials defined in the material configuration dialog.

Material management

The recipe editor dialog ‘Configuration →Material management→Materials and groups' is available for configuring the different materials. The materials to be transported and the group to which they belong are defined here.

The new dialog ‘Configuration→Material management→Material order’ is available for defining the material order relations.

possible material order relations:

Material to material

Material to group

Group to material

Group to group

Material compatibility

A matrix of the material sequence relationships can be used at the RCS level to check whether the source product is suitable for the target product.

In addition, a check of the material compatibility can also be made in the following scenarios:

Order planning

When a tank is being selected for a batch parameter, the tanks with unsuitable content or status can be filtered out using a new online dialog.

For the batch sequence in the plant unit (sequential control)

A new interface for the material checks on the sequencer block in the AS allows 2 material IDs to be checked for compatibility:

1. Predecessor material, e.g., current material of a tank block

2. Successor material, e.g., product of the batch

3. A control bit is set in the GOP-FC in order to stop the recipe and activate the material check in the recipe server

4. A data word via which the recipe server signals the result of the material check

In the GOP-FC the result must be used to decide whether the recipe is continued, or e.g. a control request is triggered.

Profinet IO

The compatibility of SIMATIC NET ProfiNET hardware components including the associated ProfiNET communication as a process bus TCP/IP, I/O bus ProfiNET I/O and S7-S7 cross coupling TCP/IP with BRAUMAT has been tested and is released as of version V7.

Hardware components

The fundamental hardware requirement complies with the BRAUMAT hardware basis currently released (see section "Hardware requirements").

The following ProfiNET hardware components are supported:

ProfiNET automation system:

SIMATIC S7-400/CPU416-3 PN

ProfiNET I/O:

SIMATIC ET 200M/IM 153-4 PN

Supported configurations

The following communication variants are supported in connection with the CPU SIMATIC S7-400/CPU416-3 PN/DP:

Process bus for Industrial Ethernet ISO

With this the process bus can be designed as a "single" process bus or as a "dual" process bus.

Process bus Industrial Ethernet TCP/IP

With this the process bus can be designed as a "single" process bus or as a "dual" process bus.

I/O bus ProfiNET I/O

Discontinued functions

The following functions or compatibilities of the previous versions are no longer supported as of BRAUMAT V7:

The earlier "Message archive" application has been replaced with the following applications or functions as relevant:

Messages can be archived using the "Archives Manager" application.

Messages can be selected and displayed using the "Archive Viewer" application.

The so-called "Old AREA.ini format" is no longer supported. Before upgrading to version V7, any plants still running with this AREA configuration must be converted with the "SiteCfg.exe" tool available with this version

New features and changes in V6.0 SP2 as compared to version V6.0 SP1 Optional "SQL Adapter" package

With the new optional "SQL Adapter" package, it is now possible to transfer the production data from BRAUMATClassic to a higher-level SQL database based on the Microsoft SQL Server and evaluate it there for typical MIS functions (reporting, KPI calculation tracking & tracing).

The scope of the BRAUMATClassic V6.0 incl. SP2 product includes the transfer functions on the BRAUMAT IOS side, as well as server services for table handling on the DB host side, including configuration tools and documentation. The SQL database and the MIS functions themselves must be implemented as a customer- or plant-specific solution based on the Microsoft SQL Server.

The optional package is divided into the two following order items:

· SQL Adapter IOSā is required for every BRAUMAT IOS server PC from which production data is to be recorded

· SQL Adapter Serverā is required for the SQL database host PC

You can find information on HW/SW requirements and on installation and operation in the file "BM-SQL-readme.mht" on the BRAUMAT/SISTARClassic V6.0 SP2 product CD.

Enhancements and changes in V6.0 SP1 compared to V6.0

Chinese system interface and engineering texts

As of , “Chinese Traditional (PRC)” will be supported as an additional system interface language. The system resources for the Chinese language are supplied in the new directory “…\DLL.14\”. However, the language selection is not activated by default. It is activated via this setting in the file “sys.ini”:[Languages];List of languages that can be selectedNumbers=0,1,2,10,14;Name of language 1414=Chinese

Before the first use, please make the following settings in the Windows Regional and Language Options:

For "Language used in menus and dialogs", select "English", if you have set the language of the interfaces to English.

For "Language used in menu and dialogs" select "English" or "Chinese (simplified)", if you have set the language of the interfaces to Chinese.

For "Standards and formats", select "Chinese (PRC)".

When you change the "Language for menus and dialogs", the character set is not always changed also. We therefore recommend that you select the setting "Windows Classic" again and apply it in the Control Panel under "Display", "Display properties", "Designs".

Expansion of the setpoints per recipe step

The recipe setpoints per recipe step have been expanded as follows.

13 DFMs per BOP for SIMATIC S5 and S7 PCUs with RecV3

20 DFMs per BOP for SIMATIC S7 PCUs with RecV5

24 DFMs per sequencer for all versions

The views and dialogs in the Recipe Editor and the process cell overview have been extended accordingly. For new installations and upgrades of existing systems, the following must be taken into consideration:

New system: no special considerations

Upgrade/expansion of an existing system: two options

with use of this feature: the new DB 713 must be installed in the PLCs If the new DB 713 is not installed, the following behavior will occur:a) AS area length error but no AS stop because the error is intercepted in OB121 (for this purpose, however, OB121 which was supplied with the system must be loaded to the PLC please check that this is the case)b) No step protocol from a BOP that uses 14 or more DFMs

without use of this feature: No special considerations in this case. However, 14 or more DFMs can be entered for S7 PCUs in the Recipe Editor. If this nevertheless occurs, the same behavior as previously described applies.

Procedure for upgrading and using this feature:

When updating a plant with redundant server and multiple clients, the following sequence must be observed:

Install new DB 713 on all S7 PCUs

Upgrade both servers

Upgrade clients

Extend recipes, if necessary, only after completion of the above steps

Important recommendation:

Proceed in the same way on all PCUs

If possible, hold all chains in order to avoid a missing step protocol

New UnitCtrl OCX views and functions

Unit OCX has received the following functions:

New “Line can be configured” view

New “Window can be configured” view

In these new views, the user can configure the size, contents and positions of the information objects shown as display variants in a configuration file (“Unitctrl.ini” on system delivery).

The respective configuration file and display variant are defined in the configuration dialog of the faceplate instance.

In the configuration file, 3 line and 2 window display variants are preset by the system (minimum and maximum number of objects in each case) which can be used further in any way by the configuration engineer.

Additional display of max. 3 DFM values (SW or IW) in the new views

Additional display of max. 3 bit variables in the new views

New button for automatic/manual switchover of the sequence

When you click in the runtime view, an additional window opens containing all operator control options.

The unit assigned via interconnection by means of the configuration dialog can be temporarily overwritten.

Requirement: The attribute 'Operable' has been enabled in the configuration dialog

The new unit is selected in the 'Sequence' list box

Recipe Editor

Behavior of the recipe overview

The tree view in the recipe overview, in particular with regard to the navigation and operator control, was adapted to the Windows standard.

Recipe overview:Contains the recipe categories as well as the respective assigned master recipes and recipe procedures in a tree view. Furthermore, the “free” or not yet assigned recipe procedures are listed. Clicking on a master recipe or a recipe procedure opens a preview window initially.

Master recipe view:Opened with a double-click on a master recipe. It contains the master recipe header, the process parameter list and the process input list.

Recipe procedure view:Opened with a double-click on a recipe procedure. In its initial state, it contains the graphical recipe procedure, the recipe unit procedure list and the setpoints for the selected recipe unit procedure.

Editing functions in the recipe procedure

In addition, the following new editing functions are possible for recipe procedures:

(The functions are only available for 'normal' recipe operations and NOPs - no synchronisations, alternatives, jumps, jump destinations)

CutIn the recipe unit procedure, the recipe operation at the current cursor position is copied to the buffer and deleted from its original location.

CopyIn the recipe unit procedure, the recipe operation at the current cursor position is copied to the buffer.

PasteThe last recipe operation to be copied to the buffer is inserted just after the current cursor position.

Copying master recipes

The new menu command ‘Save as…’ enables you to copy master recipes.

Selecting a master recipe causes a dialog for duplicating the master recipe to appear. You must specify the name of the new master recipe.

The following options are available for the ID:

Append (new ID=<x>) → generates a new (consecutive) master recipe ID

Overwrite deleted master recipe → the list of deleted master recipes is active. When you select a line and confirm with the 'OK button', it is overwritten with the new master recipe and loses the "deleted master recipes" status.

Shared view of messages and operator actions

The 'ProView.exe' application allows you to display and print messages as well as recorded process operations and configuration changes together in one table.

The associated archive files of the selected type and period (based on days) can be searched and displayed based on individual filter criteria and column settings, and can also be sorted by column.

This application replaces the previous ‘Change logging’ application. After the new installation of a system, this application is therefore called “Archive viewer” in the BRAUMAT menu. When existing systems are updated, the menu entry is not changed, but a double-click on the “Change logging” application starts the new application. The user can update the menu entry as described in the ‘03_Administration’ manual, chapter ‘Basic Menu / Configuration’.

Scaling process pictures

In the process picture editor “Biko.exe” under Tools / Picture conversion, a dialog is available for scaling, i.e. adapting one of more process pictures to new screen resolutions, with the following properties.

The display of the background image is scaled to the new image resolution(the resolution of the image file itself, however, remains unchanged).

The positioning of the image objects is recalculated based on the image resolutions (old/new).

Additional correction factors for the x-axis (horizontal) and y-axis (vertical) can be specified for the positioning.

Empty areas (Offset) can be specified for the four page sides.

Extracting text attributes from the STEP 7 symbol table

Using the new "ZL_Synchronizer.exe" tool, text parameters (instance names, descriptions) of certain object classes can be extracted based on the PCU from the exported symbol table "S7_sym.seq" of the SIMATIC Manager. Duplicate creation of the texts in two places therefore becomes unnecessary.

Conversely, instance names and descriptions from the text parameter assignment can also be written back into the "S7_sym.seq" file.

Other information and changes

Recipe server power-up when there is no clear configuration in the PCUsIf no clear recipe server configuration is detected in the assigned PCUs during power-up (for example, when AS is reloaded on a PCU), the first server in the AREA automatically powers up as the recipe server. To this end, automatic server switchover must be enabled in the configuration file …\windcs\sys\recipe.ini.[ServerSupervising]AutomaticServerActivation=1This switchover is enabled by default (factory settings). In the case of an update, you should check this setting and change it if necessary.

In the interconnection of picture objects with the image design (“BiKo.exe” application), the block types (SB, PB, FB, FX, OB) are removed from the data connection dialog.

BRAUMAT Shell: Start of the desktop.If BRAUMAT is started under Windows 7 or Server 2008 as Shell (see manual 02_Installation and configuration, chapter “Start the system from the Shell”) and UAC (“User Account Control” / Windows standard setting) is enabled, the standard Windows desktop can no longer be enabled via the "Program Manager" menu item of the basic menu; only Windows explorer is started. Remedy:Disable “UAC” in the Windows Control Panel under “User Accounts / Change User Account Control settings” by dragging the slider to “Never notify”.

Excel import/export Configuration of offline data via MS Excel has been tested and released for Excel 2003. We also do not expect any compatibility problems to occur in newer versions of MS Excel.

Information for special consideration:

Resetting a SIMATIC S5 PCU blocks the PCU_Server.If you trigger a reset for a coupled SIMATIC S5 PCU, the other PCU server connections will also be blocked. No more variables will be updated, either by S5 or S7 PCUs.

Dealing with the “Stuxnet” malware:Due to the use of SIMATIC NET standard connection components, the PCU server connection to the SIMATIC S7 PCUs is subject to the same problems as other Siemens automation solutions. You can obtain information on current developments and on measures recommended by Siemens for handling Stuxnet here.http://support.automation.siemens.com/WW/view/en/43876783

Options and tools that are no longer included on the supplied CD

The scope of the functions and applications provided by the current product is defined by the software contained on the supplied CD and the documentation included in the delivery. Tools that may have been supplied in earlier versions as well as project-specific options are therefore no longer included on the current CD and/or in the documentation. These include, for example, conversion tools for recipe/material definitions/messages from previous versions (convert.exe, conv4To5.exe, histconv.exe). These can be obtained via SIMATIC Customer Support, if required. You can contact Technical Support for all "Industry Automation and Drive Technology" products via the Web formhttp://www.siemens.com/automation/support-request

Enhancements and changes in V6.0 compared to V5.3 SP3

New Operating system variants

BRAUMAT/SISTARClassic V6.0 SP1 supports the following operating system variants:

· Microsoft Windows XP Professional + SP3

· Microsoft Windows Server 2003 R2 + SP2 or without R2 as workstation

· New! Microsoft Windows 7 Ultimate SP1 (32-bit/64-bit)

· New! Microsoft Windows Server 2008 SP2 (32-bit)

· New! Microsoft Windows Server 2008 R2 SP1 (64-bit)

Error correction for RCS

The conversion of the number format from "DoubleWord" to the number format "Word" was faulty and has been corrected.

Number of the BOP associations for line recipes increased

The maximum number of BOP associations for line recipes in the file bopass.dbf has been increased from 32767 to 65535.

Information on changes in previous versions

Changes in V5.3 SP1 compared to V5.3

Functional enhancements / problem solutions

Optimized recipe printout in graphical and list format

Excel Import/Export and worksheet for all BRAUMAT technology objects(refer to the 06_Engineering based on S7.pdf Manual, chapter 6)

Improved handling in the BRAUMAT "Recipe Editor"Hiding/showing of basic recipes which are not required Improved visualization and handling of process parameters (grayed out fields in the MR list view; scaling selection box YES/NO; defined handling of min/max values and decimal points)

TagLogging, input/ output/ source tags can be defined in the MWBL Editor (refer to the 13_Chargenkurven.pdf Manual, chapter 5)

Notes with regard to the Recipe Editor

Master recipes which are no longer required (e.g. on completion of the IBS phase) can be deleted from the recipe overview. (Select MRāFile menuāDelete master recipe). Deleted MRs are no longer displayed in order to obtain a clear Recover Masteroverview. However these can be recovered as required (File menu Recipe)

The visualization and handling of process parameters was improved (grayed out fields in the MR list view; scaling selection box YES/NO; defined handling of min/max values and decimal points)

Observe when creating a new recipe procedure (or when using the "Save as" function to save existing ones) which contains substitute job parameters that a previously defined recipe category must be available and referenced, for you will otherwise lose the substitution (refer to the note in the 10_Recipe_System Manual, chapter 2.3.3.1).

Caution:You may only toggle the recipe status 'Enable production' to a different status (e.g. to 'in progress' in order to make changes) if there are no active batches using this RP. You may otherwise risk "hang-ups" of active batches, for example, if you are making changes to synchronizations or alternatives in the RP and then save these changes.

Icons with 24-bit, 8-bit or 4-bit color depth are supported. However, it is advisable for reasons of performance to use 4-bit or 8-bit color depths.

Compatibility is only ensured if the bitmaps are saved using the "Paintbrush" tool of Windows NT, or "Microsoft Paint" as of Windows 2000.

Observe the specified formats/color depths if using other tools such as COREL-DRAW

It is advisable to save the bitmaps once again using "Microsoft Paint" if you have any problems with their visualization

Caution: The "Tool" menu of the BRAUMAT "Picture creation" application (BIKO.exe) contains an entry for calling customizable a bitmap editor. Windows "Paintbrush" may still be linked in this application after you update an earlier system version. It is advisable to use the newer Windows tool "MSPAINT.exe". Edit the corresponding information in the BRAUMAT configuration file "<DRIVE>:\windcs\sys\BIKO.INI" in order to be able to start the current Bitmap Editor.

Certain visualization objects (line colors, bar graph output) require precise background colors (example: Black must be RGB( 0, 0, 0 )). The visualization objects mentioned will not work as expected if the color values do not precisely coincide with the values you configured.

Caution: In addition to the BMP format, BRAUMAT/SISTARClassic also supports the compressed and space-saving JPEG (*.JPG) format. However, the development of pixel errors or color hue offset may be expected, as this compression format leads to picture data losses. Functional errors at the line and bar graph OCX must be expected. For this reason it is advisable not to use the JPG format for these control elements.

Enhancements and changes in SP2 compared to V5.3 SP1

Multi-area capability of applications / AREA dialog

It was inevitable alongside with the introduction of the area concept in BRAUMAT to retain multiclient capability of the applications. This functionality was already implemented for certain applications in V5.3. Service Pack 2 now implements the remaining applications listed below:

Name Editor

Step sequence logs

ESG overview

Controller

Maintenance data

Status S5+S7

Controlling

DB Editor

Special values

Entitydef.exe (for configuring the "line entity" type)

AREA selection dialog at the start of applications

The following dialog sequence is set at the start of applications:

A selection dialog box which displays the configured AREAs is initially output

After the user has selected an AREA (default = previously selected AREA) and confirmed this selection with OK, the application is started and goes online to the relevant AREA server

If you select the "Do not show this dialog in future" check box, the last selection is retained in memory and the dialog is no longer output for this application

You can reactivate this dialog with <Ctrl>+double-click on the application

AREA selection dialog with File > Open

The AREA selection dialog is not opened until the user selects the File > Open command if starting applications which open by default with blank workspace.

Retention:

The local AREA is set by default before you define an AREA reference. The selected AREA, that is, the AREA selection will be saved after that.

The last instance of several opened instances of an application "takes priority"

Multi-AREA mixed pictures

Objects which are interconnected in a process picture can be referenced to data sources of different AREA servers (so-called mixed picture)

The process picture is loaded and edited by running the "BIKO.exe" application on any MC-Client/MC-Server of a specific AREA. The actual process picture may be stored on all servers of a different AREA (it is not required to copy process pictures).

The properties dialog boxes of the graphic objects contain a new "AREA" combo box (default=own or previously selected AREA, similar to PCU). After you selected this combo box, only the PCUs of this AREA are displayed in the "PCU" combo box.

Multi-AREA mixed pictures can now be opened in Runtime by running the "LZSYS.exe" application on any MC-Client/MC-Server of a specific AREA, regardless of whether or not these process pictures and their interconnected objects are stored on the servers of a different AREA.

Note:

For additional information, including information about "Global AREA picture navigation with panel faceplate", refer to the "15_Operating and Control based on S7.pdf" Manual.

New analog faceplate V2

The new analog faceplate V2 is available after installation or after an update to Service Pack 2 (...\windcs\sys\ocx\analog2.ocx). In addition to the previous functionality of PCUs type SIMATIC S7, you can now create interconnections to any AS data source (input, output, flag, data block) of Bit, Byte, Word, or Dword format. In order to enable selection of the control element as picture object in the "BIKO" application, you must add a corresponding entry to the configuration file "...\windcs\sys\ocx\sisctrls.ini". The required text line is available in the original file "<DRIVE:>\sis_sys\SISTAR\windcs32.usr\sys\ocx\sisctrls.ini" on the Toolset CD. You can copy the complete INI file from "...windcs\sys\ocx\...", provided it was not adapted to a specific project (for additional information on Analog Control V2, refer to the "15_Operating and Control based on S7.pdf" Manual, chapter 1.3.3 Analog Faceplate V2).

New message faceplate (msgview.ocx)

Messages can be selected by means of an SQL filter string in the "Filter expression" field.

An expression with correct syntax is prerequisite. You can check this using the "Verify" button.

All messages of the active area are displayed if the filter string remains blank.

The message elements listed at "Field names" are available for use as filter criteria.

The logic operators AND/OR are availableAn additional operator IN ... (e.g. type IN 'FBM') is available for TYPE (message type). This represents an OR operator for the different message types

The "Simple unit filter" can be used to open a dialog box which displays selection boxes. This functionality also allows users without SQL knowledge to set the filter string by selecting the corresponding filter criteria

For further information, refer to the "15_Operating and Control based on S7.pdf" Manual, chapter 1.3.9 Message Faceplate.

Client-specific folders on server IOS

Users now have the option of creating a subfolder (IOS.XXX) for each client on the server to which client-specific settings and process pictures can be saved.

Example:

..\windcs\IOS.102\etc\kpos001.ini Area definitions for the plant overview

Information is read from the server as soon as a client folder exists (e.g. Open picture dialog in LZSYS, or in the "Plant" menu in SEQCtrl) – the behavior is otherwise as in the previous case. This functionality also allows you to manage/save AREA-relevant, specific client pictures on the server.

Display and filter functions in the "Parameterization" application

The new "A.type" column was added to the tabular view of object attributes. This view shows the type of access of the specific object parameter as defined in the "param.pcu" system files. An additional color marking facilitates classification (engineering / system / runtime attribute)

The new buttons and filter functions of the toolbar facilitate daily parameterization and diagnostics tasks Hide / show extended attributes Hide / show configurable attributes Hide / show system attributes Hide / show runtime attributes

Multiclient: New or enhanced functions

Fault acknowledgment limited to AREA

The fault acknowledgment functions (ESG/horn) were changed in the applications as of BRAUMAT/SISTARClassic V5.3 SP2. The new acknowledgment function only affects the following PCUs, depending on the application:

active AREA for applications with AREA selection

local AREA for applications without AREA selection (e.g. PCU server, basic menu)

BIKO saves changes to process pictures on both servers

Process picture changes are always stored redundant - that is on Server-1 and Server-2, independent of whether the picture was opened on the Multiclient/MC-Server or locally on the server. Precondition for that is the following key setting in file ‘BIKO.INI’:

[Options]

;Copy files to all GP_PROJ paths after saving files

CopyFilesToAll=1

Status S5 and Status S7 in the Application menu

After installation of BRAUMAT/SISTARClassic (delivery state) the "Program service tools" tab of the main menu contains two icons named "Status S5" and "Status S7".

"Status S5" is logically linked by default with the BRAUMAT application "Status.exe".After having been opened using the File > Open command, this application only displays PCUs of the type SIMATIC S5.

"Status S7" is logically linked by default with the BRAUMAT application "Status_S7.exe". In addition to the actual status function, it can be used optionally to open the LAD/FBD/FUP Editor of the STEP 7 programming package, provided this package is installed on the PC station and if selected in the configuration dialog.

(for additional information about the new dialog functions, refer to the "16_Application based on S7.pdf" Manual, chapter 11 ...et. seq.)

Redundant terminal bus

The terminal bus interconnects the server and clients of the process control system. The configuration of a redundant terminal bus may consist of two identical, separate network segments, or of two coupled terminal bus ring systems (double ring). The network components and the PC LAN adapter ensure unrestricted operation of the terminal bus. Communication via the second terminal bus is upheld if one of the terminal bus segments fails. The following two network adapters are used in all server and client PC stations to be connected to the terminal bus:

Intel Pro/1000MT server adapter

Intel Pro/1000GT desktop adapter

These network adapters operate in "Team mode" with only one TCP/IP network address. Each network adapter is connected to one of the redundant terminal bus rings. All network components are redundant.

The max. number of tags for SIMATIC S7 PCUs was increased from 2035 to 3700 (number of blocks from 55 to 100). The PCU update cycle increases accordingly (approx. 5 s) at full load.

Redundant registration of the sources is now prevented in the PCU server. This leads to a significantly "more favorable utilization of tag resources", particularly if the same process pictures have been opened at several client IOS.

DataLink.ocx: The number of sources was increased from 510 to 1200.You can now define up to 1200 tags in the faceplates per process picture.

Client.dllThe maximum number of registered variables in the client was increased from 1536 to 2500

Sistar channel: The number of sources was increased from 1200 to 3600.The active WinCC pictures now support simultaneous activation of up to 3600 BRAUMAT/Sistar tags per server or Single Station OS. (Note: Faceplates are not included as these receive their data via Datalink OCX)

Open source protocols for Access MDBs are now compatible with Office 2003

The Access database for selecting and displaying the open source protocols included with the standard installation is now compatible with Office 2003 (Access 11). Observe the following items:

The new Access application is available in the ...\windcs\Access32\Pi_Cha32.mdb folder after the update was installed

The previous Access application in ...\windcs\Access32.v70 will not be modified as it may have been extended by the user.

The new MDB is called either directly (double-click on the MDB file, desktop link/icon) or by means of the BRAUMAT menu (requires update of the configuration file "menuv460.ini"; refer to the "14_Logging.pdf manual, chapter 2.12.1 Installation application open source protocols for display and analysis"

You need at least the MS Access Runtime Kit (if a full version of MS Access is not available) which is available on the BRAUMAT/SISTARClassic Toolset CD at <DRIVE:>\sis_sys\SISTAR\Microsoft\MS_AccessRuntime_Office_2003

For further information on handling, refer to the "14_Logging.pdf Manual, chapter 2.12.1 Installation application open source protocols for display and analysis"

"Spanish" system user interface now available in the standard system

The Spanish user interface of the system which was previously enabled only for project-specific applications is now available in the standard system. Setup generates the following additional system folders with language ID "xxxxxx.2“ = Spanish:

The Operating Manuals (*.pdf), the Help system (*.chm) and specific text information and configuration files are currently only available in German and English language.

The corresponding Spanish system folders may contain files in English language if not clearly defined.

If the system function "Support change of Engineering language" is integrated in the user project, create the...\windcs\pcunnn\Texts.2 PCU-related text parameterization folder manually before you start text parameterization in Spanish language. You can copy the text files of a different PCU-specific Texts.x folder to this folder as basic entry. Text parameterization in Spanish language is then enabled based on this entry.

New "Ports list" view for PCU servers

The PCU server window now provides a selectable new view which displays information about currently loaded miniport DLLs. You change to this view by selecting the "ViewPorts list" menu. The following information is displayed in the columns:

Port Module Miniport DLL

Port Name Program module name

Port Version ‘0x0200’ from SP2 (should be the same for all miniports)

File version System version, Service Pack / Hotfix status and generate number (should be the same for all miniports)

Tele Types used telegram types

Status Running, Loaded

Path Path for the miniport DLL file

This view provides a quick overview with regard to the availability and status of the basic BRAUMAT/Sistar system services. The list must correspond with the currently active miniport configuration line in PCU_SERV.INI.

Settings required for PLCSIM mode

Asynchronous read operations should be disabled while working with PLCSim, as larger blocks such as DB725 may lead to problems. For this reason the following settings must be made in the default configuration file "…\windcs\sys\S7.INI":

[S7]

…

;Asynchronous reading from PCU

AsyncRead=0

Path references to picture objects

Path references outside of "windcs"

The references in process picture objects (tags, faceplates) to text, icon or sound files outside the BRAUMAT system folder were partially tolerated and implemented correctly in earlier system versions. This is no longer supported in BRAUMAT/SISTARClassic V5.3 SP2 or higher as this is difficult to implement technically. Any existing reference of this type will lead to the output of a fault message dialog after the corresponding process picture was called. The objects causing this fault message can be identified by means of the specified log file. Swap the referenced files to the "…\windcs" file and update the picture objects.

Path references to network drives / UNC pathnames

Path references in visualization-objects (e.g. text, icon or sound files of variables and faceplates) are redirected at runtime to the AREA server to which the PCU of the object belongs. Thus, the node-name which is displayed in the properties for some objects in ‘Biko.exe’, is replaced implicitly. This causes that the referenced info-files are always loaded from that server to which the PCU of the object is assigned, independently from where the process picture is loaded.. If –for example- in existing projects the PCU-subfolders were copied manually to other server-disks in order to achieve AREA spanning viewing & operating, this is not necessary any more for BRAUMAT/SISTARClassic V5.3 SP2.

"Param.PCU" user files on server path

User-specific "Param.PCU" files are now read from the "Project" path and may be stored on the AREA server. The server IOS (or redundant server IOS with activated path monitoring) assigned to the PCU is determined automatically for the multi-client.

"HistConv.exe" with user interface

A user interface was created in place of the command line applications. The same application name "histconv.exe" is found in the …\windcs\sys\... folder. The list view displays both the old and new version of the archive files. Archive files of the latest version are already identified by means of a green check mark. You can run a conversion at any time. The function always generates a "*.SIC" file of the latest version similar to the procedure with other editors.

"Global Logging" includes the old value after parameters were changed

The "Old value" column of the changes archive actually displayed the old value only for few changes (e.g. recipe). The column remained blank for the major part of log entries, for example, after changes to parameters, process pictures /faceplates and after setpoint changes in "SeqCtrl". These entries were added, that is, the corresponding old value is logged if changes are made to parameters / setpoints in stated applications.

Enhancements and changes in SP3 compared to V5.3 SP2

Line recipes: number of possible lines increased

The total number of lines that can be configured within an area has been increased from 255 to 999.

Step selection in plant overview and process pictures

Instead of “blind” selection by entering a step number, recipe steps are now chosen from a list that provides a plain-text display of steps in the control recipe currently being executed in a unit.

This applies for both the plant overview (SeqCtrl.exe) and process pictures (UnitCtrl.ocx).

New classes in the “Param.PCU” system files

The following classes have been added to the “Param.pcu” system files:

VMon, RC_CNF, RC_CE, RC_LE, RC_PE, RC_SE.

As a result, the following “Param.pcu” user files formerly provided as an option are no longer needed:

Vmon.pcu, RC_CNF.pcu, RC_CSPL.pcu.

These should be removed from all PCU directories!

New options in SiteCfg: “GlobLog”, “MaintSupv”, and “Entity”

The following server functions can now be managed with the “SiteCfg” configuration tool:

Change logging (GlobLog)

Maintenance data monitoring (MaintSupv)

Line entity (EntPort)

It is no longer necessary to enter the MiniPorts responsible for these functions in the “PCU_Serv.ini” file.

Simply enable the desired options in the Properties dialog of the server.

Note that the “GlobLog” and “EntPort” options can only be enabled in conjunction with recipe control.

Warning:

For compatibility reasons, priority is given to entries in the “PCU_Serv.ini”. You should therefore remove the MiniPorts “Globlog.dll”, “MaintSupv.dll”, and “EntPort.dll” from the “PCU_Serv.ini” file when using the new management system.

Instance names for S7 “Message” class

In the S7 “Param.PCU” files, the file for “Message” class instance names is now permanently stored for all languages as “Meld.txt”. In previous versions, the “Msg.txt” file was used for English and Spanish. To continue using names from an existing “Msg.txt” file, you must rename this file as “Meld.txt” in all PCU text directories.

“Permanent condition” indication on ESG faceplate

How a missing permanent condition is indicated can now be defined centrally in the “controls.ini” file. File: \windcs\sys\controls.iniKey: [ICM3] SignalInterlock=1Value 0: missing permanent condition is not indicatedValue 1: missing permanent condition is indicated (default)

Description of additional icons on ESG Faceplate

A description of additional icons available on the ESG faceplate has been added to “15_Operator Control and Monitoring Based on S7.pdf”, Section 2.3.5 ESG Faceplate.

Status display on analog faceplate V2

It is now possible to indicate the status of a measured value as a colored border on analog faceplate V2. The source of the status value (up to 32 bits) is configured on the faceplate using the new “Monitoring” properties page.

Up to 32 different border colors can be defined centrally in the “controls.ini” file.

Status value > 0: The color defined as the most significant bit in the “controls.ini” file is used.

AS cross coupling with twin bus (FB681)

If the first interface failed in the AS cross coupling with twin bus, then the second interface was switched automatically. However, no data was then received via this interface any longer. This error was remedied in FB681 from the system block library SIS_BAS_530.

Extended "Param.PCU" for S7 block "ASTA"

The missing attribute E4SendRecv’ was added for the S7 block "ASTA" in "Param.PCU". It describes the type of cross coupling used. It was not possible so far to configure it directly using the parameter settings.

Creating an S5 PCU with "SiteCfg" configuration tool

After creating a new PCU, you will be queried when saving the configuration if you want to create the associated PCU directory and want to copy a template directory to this location. You can now confirm this dialog box for a SIMATIC S5 PCU with YES. A matching template for SIMATIC S5 PCU (PCU.xxx\!S5’ folder) will then be used.

Correction of S7 TA template FBs (FB1001 to FB1064)

An additional network with the query of 'ATL' (M102.1) was added in the template FBs for the S7 unit program (FB1001 to FB1064). It ensures that a query of 'FBGO' (M101.4) will only take place with running unit.

Background: 'FBGO' is invalid when the unit ('ATL'=0) is not running.

Limiting the entries in MsgView.ocx

The maximum number of messages in MsgView.ocx can be limited using the following INI switch in the file, controls.ini:

[MSGVIEW]

;Maximum of entries to be inserted in List, MaxEntries=-1 --> all

MaxEntries=100

This now works even when a filter is set in MsgView.ocx.

Always ensure that only the messages of the current and preceding day are displayed in MsgView.ocx. Use the message archive for older messages.

'X-Tracking' operating mode at the 'PID' block corrected

The 'X-Tracking' operating mode at the 'PID' block now works as described in the manual:With X-Tracking operating mode (XTR = "1"), the internal setpoint is tracked to the actual value, XIST. This enables bumpless switchover from "external" to "internal".

This affects the following blocks:

S7: FB730 from the system library, SIS_TEC_530

S5: FB230 from the product package project, J401FLST.S5D

Interconnection of HEXA32 values in S7 blocks corrected

An INT overflow is now prevented for interconnection of 32-bit values by limiting to MAX_INT (signed) in the respective blocks. You can still interconnect to DINT, but the internal calculation only uses INTS. If MAX_INT is exceeded, the values remain at MAX_INT internally.

The following blocks can now handle full 32-bit values:

Type

Corrected block

Attribute

Internal

AOUT

FB731

SOLL

16-bit

PID

FB730

XIST

WEXT

Z

YNF

16-bit

16-bit

16-bit

16-bit

INCO

FB729

SOLL

IST

16-bit

16-bit

POLY

FB735

X

16-bit

ThreStep

FB744

XIST

WEXT

16-bit

16-bit

Process pictures: Bit number added to tooltip

The addressed type and the bit number are now also displayed in the default tooltip for bit variables.

To make this change take effect in an existing project, the following INI keys must be deleted manually in the file ...\windcs\bilder\image.ini' on the servers: